Hyundai i-30: Brake System / Front Disc Brake

Hyundai i30 (PD) 2018-2024 Service Manual / Brake System / Brake System / Front Disc Brake

Components and components location
Components

1. Caliper body
2. Guide rod pin
3. Guide rod pin boot
4. Caliper carrier
 5. Pad inner shim
6. Pad retainer
7. Brake pad
8. Pad return spring

Repair procedures
Removal
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the front wheel and tire (A) from front hub.
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

3.
Disconnect the brake hose by loosening the bolt (A).
Tightening torque :
24.5 - 29.4 N.m (2.5 - 3.0 kgf.m, 18.1 - 21.7 lb-ft)

4.
Remove the caliper body by loosening the guided rod bolt.
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

5.
Remove the pad return spring (A).

  
•
Pad return springs must be replaced with new ones whenever pads are replaced.
•
Technicians should be careful not to deform pad return springs.
•
When pad return springs are deformed, it may cause improper braking, more fuel consumption.
6.
Remove the brake pad.
7.
Remove the pad retainer (A).

  
•
When installing, use a new one return spring (A), pad retainer (B), inner shim (C).
8.
Remove the caliper carrier by loosening the caliper mounting bolts.
Tightening torque :
78.5 - 98.1 N.m (8.0 - 10.0 kgf.m, 57.9 - 72.3 lb-ft)

9.
Loosen the screw and the remove the front disc.
Tightening torque :
4.9 - 5.9 N.m (0.5 - 0.6 kgf.m, 3.6 - 4.3 lb-ft)

Replacement
Brake Pad
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the front wheel and tire (A) from front hub.
3.
Loosen the mounting bolt and then remove the brake hose from the strut assembly.
4.
Down the caliper body by loosening the guided rod bolt
5.
Remove the pad return spring (A).
6.
Remove the brake pad.
7.
Replace the pad retainer (A) with a new one.
8.
Replace the brake pad with a new one.

  
•
When installing, use a new one return spring (A), pad retainer (B), inner shim (C).
9.
Install the pad return spring (A).

  
•
Pad return springs must be replaced with new ones whenever pads are replaced.
•
Technicians should be careful not to deform pad return springs.
•
When pad return springs are deformed, it may cause improper braking, more fuel consumption.
10.
Use a SST (09581-2T100) when installing the brake caliper assembly.

  
•
Connect an air hose (B) to the SST after confirming that the valve of the SST is surely closed.
•
Input the SST in the caliper and press the caliper piston while opening the valve of the SST slowly couter clock wise.
•
Close the valve (A) of the SST and disconnect the air hose (B); then, open the valve again to get the rest of air out and remove the SST from the caliper.
11.
Install the caliper body then tighten the guide rod bolt.
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

12.
Install the brake hose bracket to the front strut assembly.
Tightening torque :
8.8 - 13.7 N.m (0.9 - 1.4 kgf.m, 6.5 - 10.1 lb-ft)

13.
Install the front wheel and tire (A).
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

Guide Rod Pin and Boot
1.
Loosen the wheel nuts slightly.
Raise the vehicle, and make sure it is securely supported.
2.
Remove the front wheel and tire (A) from front hub.
3.
Remove the caliper body by loosening the guided rod bolt.
4.
Remove the guide rod pin (A).
5.
Replace the guide rod pin boot (A) with a new one.
6.
Install the guide rod pin (A) with a new one.

  
•
Apply the grease on the guide rod pin.
Grease type : GREASE BG-1 (MG511-60)
Capacity : 0.35 - 0.8 g
•
If apply the grease excessively, would not be assembled the guide rod pin.
7.
Install the caliper body.
Tightening torque :
21.6 - 31.4 N.m (2.2 - 3.2 kgf.m, 15.9 - 23.1 lb-ft)

8.
Install the front wheel and tire (A).
Tightening torque :
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)

Inspection
Front brake disc thickness check
1.
Check the brake pads for wear and fade.
2.
Check the brake disc for damage and cracks.
3.
Remove all rust and contamination from the surface, and measure the disc thickness at 24 points, at least, of same distance (5mm) from the brake disc outer circle.
Front brake disc thickness
- Standard : 23 mm (0.90 in), 25 mm (0.98 in)
- Service Limit
23mm : 21 mm (0.82 in), 21.4 mm (0.84 in)
25mm : 22.6 mm (0.88 in), 23 mm (0.90 in)
Deviation : Less than 0.015 mm (0.0002 in)

4.
If wear exceeds the limit, replace the discs and pad assembly left and right of the vehicle.
Front Brake Pad Check
1.
Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Front brake disc thicknessPad thickness
Standard : 10.5 mm (0.41 in), 13 mm (0.51 in)
Service Limit : 2.0 mm (0.78 in)
2.
Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
Front brake disc runout check
1.
Place a dial gauge about 10mm (0.2 in.) from the outer circumference of the brake disc, and measure the runout of the disc.
Brake disc runout
Limit : 0.050 mm (0.0016 in.) or less (new one)

2.
If the runout of the brake disc exceeds the limit specification, replace the disc, and then measure the runout again.
3.
If the runout does not exceed the limit specification, install the brake disc after turning it 180° and then check the runout of the brake disc again.
4.
If the runout cannot be corrected by changing the position of the brake disc, replace the brake disc.
Installation
1.
To install, reverse the removal procedure.
2.
Use a SST (09581-2T100) when installing the brake caliper assembly.

  
•
Connect an air hose (B) to the SST after confirming that the valve of the SST is surely closed.
•
Input the SST in the caliper and press the caliper piston while opening the valve of the SST slowly couter clock wise.
•
Close the valve (A) of the SST and disconnect the air hose (B); then, open the valve again to get the rest of air out and remove the SST from the caliper.
3.
After installing, bleed the brake system.
(Refer to Brake System - "Brake System Bleeding")
(Refer to Brake System - "ABS System Bleeding")
(Refer to Brake System - "ESP System Bleeding")

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